U.S. patent number 7,169,249 [Application Number 10/382,798] was granted by the patent office on 2007-01-30 for method of joining textile elements.
This patent grant is currently assigned to Nike, Inc.. Invention is credited to Matt Nordstrom.
United States Patent |
7,169,249 |
Nordstrom |
January 30, 2007 |
Method of joining textile elements
Abstract
A method of joining a first textile element and a second textile
element is disclosed. The method includes four general steps:
First, the first textile element, the second textile element, and
an adhesive element are formed. Second, a bond is formed between
the first textile element and the adhesive element to define a
bonded area and an unbonded area. Third, an aperture is formed in
the first textile element and the adhesive element by removing at
least a portion of the bonded area. Fourth, a bond is formed
between the second textile element and the bonded area, thereby
joining the first textile element and the second textile
element.
Inventors: |
Nordstrom; Matt (Portland,
OR) |
Assignee: |
Nike, Inc. (Beaverton,
OR)
|
Family
ID: |
32926969 |
Appl.
No.: |
10/382,798 |
Filed: |
March 5, 2003 |
Current U.S.
Class: |
156/256; 156/334;
156/514; 156/563; 428/131; 428/138; 428/200 |
Current CPC
Class: |
A41D
27/08 (20130101); A41D 27/204 (20130101); A41D
27/245 (20130101); B29C 65/18 (20130101); B29C
65/4815 (20130101); B29C 65/5057 (20130101); B29C
65/5071 (20130101); B29C 66/1122 (20130101); B29C
66/24 (20130101); B29C 66/729 (20130101); D06M
17/04 (20130101); D06M 23/18 (20130101); D06Q
1/00 (20130101); B29C 66/472 (20130101); B29C
66/4724 (20130101); B29C 66/8322 (20130101); B29C
65/04 (20130101); B29C 65/08 (20130101); B29C
66/30623 (20130101); B29C 66/43 (20130101); B29K
2067/00 (20130101); B29K 2313/00 (20130101); B29L
2031/772 (20130101); Y10T 156/1761 (20150115); Y10T
428/24843 (20150115); Y10T 156/1309 (20150115); Y10T
428/24273 (20150115); Y10T 156/1062 (20150115); Y10T
428/24331 (20150115); B29C 66/71 (20130101); B29C
66/71 (20130101); B29K 2067/00 (20130101) |
Current International
Class: |
D04H
1/00 (20060101); B32B 37/02 (20060101) |
Field of
Search: |
;156/256,513,514,563,252,253,334 ;264/152,153,155,156,154
;428/131,138,200 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
2316353 |
|
Feb 1996 |
|
GB |
|
2 312 643 |
|
Nov 1997 |
|
GB |
|
4308277 |
|
Oct 1992 |
|
JP |
|
Other References
Website pages from Bemis Associates Inc. (copyrighted 1998-2002) (5
pages). cited by other .
"General Guidelines for Using Heat Seal Film Adhesive in Embroidery
Applications" from Bemis Associates (Revised Feb. 2000) (8 pages
total). cited by other.
|
Primary Examiner: Gray; Linda
Attorney, Agent or Firm: Banner & Witcoff, Ltd.
Claims
That which is claimed is:
1. A method of joining a first textile element and a second textile
element, the method comprising steps of: shaping the first textile
element to have greater area than the second textile element and an
adhesive element; forming a first bond between the first textile
element and the adhesive element by heating the adhesive element
and the first textile element to define a bonded area and an
unbonded area, the first bond being located in a spaced
relationship with at least some of outer edges of the first textile
element; defining an aperture in the first textile element and the
adhesive element by removing at least a portion of the bonded area;
and forming a second bond between the second textile element and
the bonded area, thereby joining the first textile element and the
second textile element.
2. The method of claim 1, wherein the step of forming the first
bond includes applying pressure to the adhesive element and the
first textile element.
3. The method of claim 1, wherein the step of forming the first
bond includes applying pressure with a platen of a heated
press.
4. The method of claim 1, wherein the step of forming the first
bond includes locating the first bond in a spaced relationship with
all outer edges of the first textile element.
5. The method of claim 1, wherein the step of defining the aperture
includes locating the aperture entirely within the bonded area.
6. The method of claim 1, wherein the step of defining the aperture
includes locating the aperture at least partially within the bonded
area.
7. The method of claim 1, wherein the step of defining the aperture
includes dimensioning the aperture to have proportions that are
substantially similar to proportions of the adhesive element.
8. The method of claim 1, wherein the step of defining the aperture
includes locating the aperture to form a thin border of the bonded
area around the entire aperture.
9. The method of claim 1, wherein the step of defining the aperture
includes locating the aperture to form a thin border of the bonded
area around at least a portion of the aperture.
10. The method of claim 1, wherein the step of defining the
aperture includes die cutting the aperture.
11. The method of claim 1, wherein the step of forming the second
bond includes locating the second textile element in a spaced
relationship with at least some outer edges of the first textile
element.
12. The method of claim 1, wherein the step of forming the second
bond includes heating the adhesive element and the second textile
element.
13. The method of claim 12, wherein the step of forming the second
bond includes applying pressure to the adhesive element and the
second textile element.
14. The method of claim 12, wherein the step of forming the second
bond includes applying pressure with a platen of a heated
press.
15. The method of claim 1, further including a step of shaping the
second textile element and the adhesive element to have
substantially similar dimensions.
16. The method of claim 1, further including a step of selecting
the adhesive element to include a thermoplastic polymer
material.
17. A method of joining a first textile element and a second
textile element, the method comprising steps of: shaping the second
textile element and a thermoplastic adhesive element to have
substantially similar dimensions, and shaping the first textile
element to have greater area than the second textile element and
the adhesive element; forming a first bond between the first
textile element and the adhesive element through the application of
heat and pressure to define a bonded area and an unbonded area, the
bonded area being located in a spaced relationship with at least
some outer edges of the first textile element; defining an aperture
in the first textile element and the adhesive element by removing
at least a portion of the bonded area, the aperture being located
substantially within the bonded area; and forming a second bond
between the second textile element and the bonded area through the
application of heat and pressure, thereby joining the first textile
element and the second textile element.
18. The method of claim 17, wherein the step of shaping includes
selecting the adhesive element to include one of a group consisting
of polyamide, polyester, polyolefin, and vinyl.
19. The method of claim 17, wherein the step of shaping includes
selecting the adhesive element to include a polyurethane
material.
20. The method of claim 17, wherein the step of forming the first
bond includes locating the bonded area in a spaced relationship
with all outer edges of the first textile element.
21. The method of claim 17, wherein the step of defining the
aperture includes dimensioning the aperture to have proportions
that are substantially similar to proportions of the adhesive
element.
22. The method of claim 17, wherein the step of defining the
aperture includes die cutting the aperture.
23. The method of claim 17, wherein the step of defining the
aperture includes locating the aperture entirely within the outer
edges of the first textile element.
24. A method of joining a first textile element and a second
textile element, the method comprising steps of: shaping the second
textile element and a thermoplastic polyurethane adhesive element
to have substantially similar dimensions, and shaping the first
textile element to have greater area than the second textile
element and the adhesive element; forming a first bond between the
first textile element and the adhesive element through the
application of heat and pressure to define a bonded area and an
unbonded area, the bonded area being located in a spaced
relationship with outer edges of the first textile element;
defining an aperture in the first textile element and the adhesive
element by removing at least a portion of the bonded area, the
aperture being located entirely within the bonded area, and the
aperture having proportions that are substantially similar to
proportions of the adhesive element; forming a second bond between
the second textile element and the bonded area through the
application of heat and pressure, thereby joining the first textile
element and the second textile element; and incorporating the first
textile element, second textile element, and adhesive element into
an article of apparel.
25. The method of claim 24, wherein the step of forming the first
bond includes applying the heat and the pressure with a platen of a
press.
26. The method of claim 24, wherein the step of defining the
aperture includes die cutting the aperture.
27. The method of claim 24, wherein the step of forming the second
bond includes applying the heat and the pressure with a platen of a
press.
28. A method of joining a first textile element and a second
textile element, the method comprising steps of: shaping the second
textile element and a thermoplastic adhesive element to have
substantially similar dimensions, and shaping the first textile
element to have greater area than the second textile element and
the adhesive element; forming a first bond between the first
textile element and the adhesive element through the application of
heat and pressure with a platen of a press to define a bonded area
and an unbonded area, the bonded area being located in a spaced
relationship with at least some outer edges of the first textile
element; defining an aperture in the first textile element and the
adhesive element by removing at least a portion of the bonded area,
the aperture being located substantially within the bonded area;
and forming a second bond between the second textile element and
the bonded area through the application of heat and pressure,
thereby joining the first textile element and the second textile
element.
29. A method of joining a first textile element and a second
textile element, the method comprising steps of: shaping the second
textile element and a thermoplastic adhesive element to have
substantially similar dimensions, and shaping the first textile
element to have greater area than the second textile element and
the adhesive element; forming a first bond between the first
textile element and the adhesive element through the application of
heat and pressure with a platen of a press to define a bonded area
and an unbonded area, the bonded area being located in a spaced
relationship with all outer edges of the first textile element;
defining an aperture in the first textile element and the adhesive
element by removing at least a portion of the bonded area, the
aperture being located substantially within the bonded area; and
forming a second bond between the second textile element and the
bonded area through the application of heat and pressure, thereby
joining the first textile element and the second textile element.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for joining textile
elements. The invention concerns, more particularly, a method of
utilizing a polymer adhesive to join textile elements in
applications such as apparel.
2. Description of Background Art
Textiles may be defined as any manufacture from fibers, filaments,
or yarns characterized by flexibility, fineness, and a high ratio
of length to thickness. Textiles generally fall into two
categories. The first category includes textiles produced directly
from webs of fibers by bonding, fusing, or interlocking to
construct non-woven fabrics and felts. The second category includes
textiles formed through a mechanical manipulation of yarn, thereby
producing a woven fabric.
Yarn is the raw material utilized to form textiles in the second
category. In general, yarn is defined as an assembly having a
substantial length and relatively small cross-section that is
formed of at least one filament or a plurality of fibers. Fibers
have a relatively short length and require spinning or twisting
processes to produce a yarn of suitable length for use in textiles.
Common examples of fibers include cotton and wool. Filaments,
however, have an indefinite length and may merely be combined with
other filaments to produce a yarn suitable for use in textiles.
Modern filaments include a plurality of synthetic materials such as
rayon, nylon, polyester, and polyacrylic, with silk being the
primary, naturally-occurring exception. Yarn may be formed of a
single filament (conventionally referred to as a monofilament yarn)
or a plurality of individual filaments. Yarn may also be formed of
separate filaments formed of different materials, or the yarn may
be formed of filaments that are each formed of two or more
different materials. Similar concepts also apply to yarns formed
from fibers. Accordingly, yarns may have a variety of
configurations that generally conform to the definition provided
above.
Separate textile elements, whether classified within the first or
second category, are often joined to produce a variety of consumer
articles, including apparel, for example. Conventionally, the
textile elements are joined through stitching, which is the
interweaving of a yarn through two or more textile elements to
secure the textile elements together. Although stitching may be
accomplished by hand, which is recognized as a labor-intensive and
inefficient process, sewing machines are generally utilized to
stitch the textile elements together, thereby forming a seam
between the textile elements.
Stitching is the most prevalent method of joining textile elements
in modern industry. The process of stitching and the resulting
stitched area, however, are subject to certain limitations. For
example, sewing machines are generally configured to form a linear
or gradually curving seam, rather than highly-curved or angular
seams, thereby limiting the configuration of the resulting product.
In addition, the edges of the textile elements may unravel if not
properly surged, hemmed, or turned during the stitching process,
which adds technical difficulty to the stitching process and may
result in defective articles if not properly executed. Furthermore,
many seams may include three or more layers of textile, due to
hemming or turning of the textile elements, which increase the
thickness of the seam and may represent areas of discomfort in the
article.
As an alternative to stitching the edges of textile elements
together, Bemis Associates, Inc. of Shirley, Mass., United States
manufactures polymer heat seal seam tapes that may be utilized to
reinforce seams, replace stitching, bond labels and embroidery to
garments, and prevent fraying, for example. The seam tapes are
thermoplastic polymers that may be applied by
commercially-available taping machines and join textile elements
formed of a variety of materials, including polyester, cotton, and
blended fabrics that include both polyester and cotton fibers, for
example.
SUMMARY OF THE INVENTION
The invention is a method of joining a first textile element and a
second textile element. As an initial step in the method, the first
textile element, the second textile element, and an adhesive
element are provided. A first bond is then formed between the first
textile element and the adhesive element to define a bonded area
and an unbonded area. An aperture is then defined in the first
textile element and the adhesive element by removing at least a
portion of the bonded area. Finally, a second bond is formed
between the second textile element and the bonded area, thereby
joining the first textile element and the second textile
element.
The first textile element is generally larger than the second
textile element and the adhesive element. In one configuration, the
second textile element and the adhesive element are formed to have
substantially similar dimensions. The relative sizes of the various
elements leads to a structure wherein the adhesive element and
second textile element are located in a spaced relationship with
edges of the first textile element. Accordingly, the position of
the second textile element is generally within an interior portion
of the first textile element, rather than on an edge of the first
textile element. In other configurations, however, the second
textile element and the adhesive element may have different
dimensions, and the second adhesive element may be located on an
edge of the first textile element.
The primary purpose of the adhesive element is to form a bond with
the textile elements, thereby joining the first textile element and
the second textile element. By configuring the second textile
element and the adhesive element to have similar dimensions, and by
defining the aperture within the bonded area, the adhesive element
is shaped and sized to contact at least the perimeter of the second
textile element to form the second bond.
The bonds between the adhesive element and the textile elements are
generally formed through heat and pressure, but may also be formed
through radio frequency or ultrasonic bonding processes. The amount
of heat and pressure applied to form the bonds depends upon the
specific material utilized for the adhesive element, which may be a
thermoplastic polymer, such as polyurethane, polyamide, polyester,
polyolefin, and vinyl. In general, the heat and pressure induces
the adhesive element to infiltrate the structure of the textile
elements. Upon subsequent cooling, the adhesive element becomes
securely bonded to the textile elements.
The advantages and features of novelty characterizing the present
invention are pointed out with particularity in the appended
claims. To gain an improved understanding of the advantages and
features of novelty, however, reference may be made to the
following descriptive matter and accompanying drawings that
describe and illustrate various embodiments and concepts related to
the invention.
DESCRIPTION OF THE DRAWINGS
The foregoing Summary of the Invention, as well as the following
Detailed Description of the Invention, will be better understood
when read in conjunction with the accompanying drawings.
FIG. 1 is a plan view depicting a first surface of an article
formed in accordance with a method of the present invention.
FIG. 2 is a plan view depicting a second surface of the
article.
FIG. 3 is a cross-sectional view, as defined by lines 3--3 in FIGS.
1 and 2.
FIG. 4 is an exploded perspective view of the article.
FIG. 5 is a plan view of an article of apparel formed in accordance
with the method.
FIG. 6 is a plan view of a first textile element, a second textile
element, and an adhesive element in accordance with a first step in
the method.
FIG. 7 is a side elevational view of the first textile element,
adhesive element, and a bonding apparatus prior to a second step in
the method.
FIG. 8 is a plan view of the adhesive element bonded to the first
textile element in accordance with the second step in the
method.
FIG. 9 is a plan view of the first textile element and the adhesive
element in accordance with a third step in the method.
FIG. 10 is a side elevational view of the first textile element,
second textile element, adhesive element, and a bonding apparatus
prior to a fourth step in the method.
FIG. 11 is a plan view of another article formed in accordance with
the method of the present invention.
FIG. 12 is a plan view of yet another article formed in accordance
with the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Introduction
The following discussion and accompanying figures disclose a method
of joining a first textile element and a second textile element in
accordance with the present invention. The method may be
incorporated into the manufacturing of a plurality of products to
provide joined textile elements. Prior to discussing the method,
however, the structure of an article 10 and another article 10a,
which are both formed in accordance with the method, is disclosed
to provide a greater understanding of the various elements and the
configuration of the elements that are utilized in the method.
Following the discussion of the method with respect to article 10,
a pair of articles 10b and 10c are disclosed to demonstrate
variations upon the specific method utilized to for article 10.
Article 10 is depicted in FIGS. 1 4 as a generally layered
structure that includes a first textile element 20, a second
textile element 30, and an adhesive element 40. First textile
element 20 includes an outer edge 21, an inner edge 22, and an
aperture 23. Outer edge 21 defines a periphery of first textile
element 20 and is depicted in FIGS. 1 4 with a rectangular shape. A
component having the general structure of article 10 may be
incorporated into a plurality of products. Accordingly, the
specific shape of first element 20, and outer edge 21 in
particular, may vary significantly depending upon the particular
application intended for article 10. Inner edge 22 defines aperture
23 and is positioned in a spaced relationship with outer edge 21,
thereby locating aperture 23 in an interior portion of first
textile element 20. Inner edge 22 and aperture 23 are depicted in
FIGS. 1 4 as having an ovate shape. As with outer edge 21, however,
the shape of inner edge 22 and aperture 23 may vary significantly
depending upon the particular application intended for article
10.
Second textile element 30 includes an outer edge 31 that defines a
periphery of second textile element 30. The configuration of second
textile element 30, and outer edge 31 in particular, is
proportional to aperture 23, but the dimensions of second textile
element 30 are greater than the dimensions of aperture 23.
Accordingly, the shape of second textile element 30 is similar to
the shape of aperture 23, but larger than aperture 23. Second
textile element 30 extends over adhesive element 40 and aperture
23, thereby covering aperture 23 and forming a different area of
article 10 that is adjacent to aperture 23.
Adhesive element 40 is positioned between elements 20 and 30 and
forms a bond with each of elements 20 and 30 to effectively join
elements 20 and 30. Adhesive element 40 includes an outer edge 41,
an aperture edge 42, and an aperture 43. Outer edge 41 coincides
with outer edge 31 of second textile element 30, and aperture edge
42 coincides with aperture edge 22 of first textile element 20.
Accordingly, adhesive element 40 is positioned at the interface of
elements 20 and 30, and adhesive element 40 is positioned entirely
between elements 20 and 30. Furthermore, aperture 43 coincides with
aperture 23, as depicted in FIG. 3, to form an opening that extends
through both first textile element 20 and adhesive element 40.
As will become apparent in the discussion of the method, outer edge
31 and outer edge 41 may be formed simultaneously or separately
through a die cutting operation, for example, so as to provide an
equally proportioned and equally dimensioned shape to both second
textile element 30 and adhesive element 40. Similarly, aperture
edge 22 and aperture edge 42 may be formed simultaneously to form
apertures 21 and 43 with equal proportions and dimensions.
First textile element 20 and second textile element 30 may be any
manufacture from fibers, filaments, or yarns, whether natural or
synthetic. Suitable textile materials for first textile element 20
and second textile element 30 are polyester, cotton, or blended
fabrics that include both polyester and cotton fibers, for example.
One purpose of the present method is to join textiles with
different properties. Accordingly, first textile element 20 and
second textile element 30 may be formed from different fibers.
Alternately, first textile element 20 and second textile element 30
may display different thicknesses or degrees of abrasion
resistance, different degrees of air-permeability, or different
colors, for example.
Adhesive element 40 may be a thermoplastic polymer that forms bonds
with first textile element 20 and second textile element 30 through
the application of sufficient heat and pressure, thereby joining
elements 20 and 30. Alternately, adhesive element 40 may be a
material that forms the bonds through radio frequency or ultrasonic
bonding processes, for example. With regard to the thermoplastic
polymer, the amount of heat and pressure applied to form the bonds
depends upon the specific material forming adhesive element 40,
which may be polyurethane, polyamide, polyester, polyolefin, or
vinyl. Suitable thermoplastic polymers formed from these materials
may be supplied by Bemis Associates, Inc. of Shirley, Mass., United
States. In general, the heat and pressure induces adhesive element
40 to soften or melt so as to infiltrate the structure of the
textile elements. Upon subsequent cooling, adhesive element 40
becomes securely bonded to each of first textile element 20 and
second textile element 30.
Article 10 has advantages over articles formed through conventional
sewing techniques. As discussed above in the Background of the
Invention, sewing machines are generally configured to form a
linear or gradually curving seam, rather than highly-curved or
angular seams, thereby limiting the configuration of the resulting
product. Article 10 includes second textile element 30 which has an
irregular, non-linear shape that is effectively joined with first
textile element 20. As will become apparent in the following
discussion, second textile element 30 may have any practical shape,
whether the shape includes angles, small-radius curves, or other
complex features.
With regard to the use of a conventional sewing machine, the edges
of the textile elements may unravel if not properly surged, hemmed,
or turned during the stitching process, which adds technical
difficulty to the stitching process and may result in defective
articles if not properly executed. Aperture edge 22 and outer edge
31, which generally form the edges located at the interface between
first textile element 20 and second textile element 30 are not
surged, hemmed, or turned to prevent unraveling or fraying.
Instead, adhesive element 40 infiltrates the structures of first
textile element 20 and second textile element 30 adjacent to edges
22 and 31, respectively, and binds the relative positions of the
various fibers, filaments, or yarns. Accordingly, adhesive element
40 serves the dual purpose of preventing unraveling and fraying and
forming bonds with first textile element 20 and second textile
element 30.
Seams formed through conventional sewing techniques often include
three or more layers of textile, due to hemming or turning of the
textile elements, which increases the thickness of the seams and
may represent areas of discomfort in the article. In contrast,
article 10 has a thickness of two textile layers, first textile
layer 20 and second textile layer 30, which provides a relatively
thin seam. Depending upon the degree of heat and pressure applied
in forming the bonds with adhesive element 40, however, adhesive
layer 40 may add a negligible increase in the thickness of the
interface between first textile element 20 and second textile
element 30.
An article 10a is depicted in FIG. 5 in order to provide an example
of an application for textiles joined through the method of the
present invention. Article 10a is an article of apparel,
particularly a shirt, that includes a trunk section 11a and two
sleeves 12a and 13a. Trunk section 11a incorporates a component
that is analogous to article 10, as described above. Accordingly,
trunk section 11a includes a first textile element 20a, a second
textile element 30a, and an adhesive element 40a. First textile
element 20a and adhesive element 40a form a plurality of apertures,
and second textile element 30a is positioned behind the apertures
and joined with first textile element 20a on an interior surface of
trunk section 11a. The combination of second textile element 30a
and the apertures in first textile element 20a and adhesive element
40a form a design in article 10a, but may also be utilized to
define numbers. Accordingly, a single aperture with a shape
corresponding with the shape of a number may be defined in first
textile element 20a and adhesive element 40a.
Article 10a may be utilized, for example, as a ventilated article
of apparel, thereby cooling the individual. First textile element
20a may be formed of a material that wicks moisture away from the
skin, thereby limiting the amount of moisture on the interior of
article 10a. Second textile element 30a may be formed of a
material, such as a mesh material, that provides a relatively high
degree of air-permeability. During exercise, therefore, air may
enter and exit the area between article 10a and the individual by
passing through second textile element 30a.
Many conventional articles of apparel incorporate mesh materials to
provide venting. In contrast with article 10a, the mesh material of
conventional apparel is often positioned between other elements of
the apparel and is joined with conventional sewn seams. Second
textile element 30a, however, is positioned within interior
portions of first textile element 20a and has an irregular,
non-linear shape that would be difficult to efficiently reproduce
with conventional sewing techniques. Furthermore, second textile
element 30a forms a functional graphic, which operates to
simultaneously ventilate article 10a and provide an aesthetic
appearance.
Second textile element 30a is exposed by a plurality of apertures
in first textile element 20a and adhesive element 40a. In
manufacturing article 10a, an individual second textile element 30a
may be utilized to extend across all apertures, or a plurality of
second textile elements 30a may be associated with each of the
plurality of apertures. Similarly, an individual adhesive element
40a may be positioned around the plurality of apertures.
Accordingly, the specific structure of article 10a may vary
significantly within the scope of the present invention.
Article 10 and article 10a provide examples of structures produced
through the method of the present invention. The following
discussion will disclose the method in terms of the various
components of article 10. One skilled in the relevant art will
recognize that concepts disclosed with respect to the method may
also be applied to article 10a or any other article requiring
textile elements to be joined, such as articles 10b and 10c, which
are disclosed below.
The method includes four general steps. As an initial step in the
method, first textile element 20, second textile element 30, and
adhesive element 40 are produced. A first bond is then formed
between first textile element 20 and adhesive element 40 to define
a bonded area and an unbonded area. Apertures 23 and 43 are then
defined in first textile element 20 and adhesive element 40,
respectively, by removing at least a portion of the bonded area.
Finally, a second bond is formed between second textile element 30
and the bonded area, thereby joining first textile element 20 and
second textile element 40. Each of the steps will be discussed in
detail in the following material.
First Step--Producing the Elements
The first step in the method is generally depicted in FIG. 6 and
involves producing first textile element 20, second textile element
30, and adhesive element 40. In general, first textile element 20
is joined with other textile elements to form an article of apparel
or other item of manufacture. Accordingly, first textile element 20
should be produced to have a shape and size consistent with the
particular application for which article 10 is being manufactured.
Similarly, the material from which first textile element 20 is
produced should be appropriate for the particular application. As
discussed above, the material may vary significantly within the
scope of the present invention to include any textile. Alternately,
first textile element 20 may have an undefined shape that may be
cut to specific dimensions during other steps of the method or
following completion of the method. Following the method, first
textile element 20 includes aperture 23. During the first step,
however, aperture 23 is absent such that first textile element 20
has a continuous configuration.
Second textile element 30 and adhesive element 40 are generally
produced to have the same dimensions. Accordingly, second textile
element 30 and adhesive element 40 may be produced simultaneously
or separately from sheet materials through a die cutting operation,
for example. The rationale behind producing second textile element
30 and adhesive element 40 to have the same dimensions relates to
the final configuration of article 10, wherein, outer edge 31 and
outer edge 41 coincide. If adhesive element 40 were larger than
second textile element 30, adhesive element 40 would be visible to
the individual and may present a non-aesthetic appearance to
article 10. If adhesive element 40 were smaller than second textile
element 30, the polymer material forming adhesive element 40 may
not infiltrate the area adjacent to outer edge 31, thereby
permitting unraveling or fraying of outer edge 31. With knowledge
of the limitations discussed above, however, second textile element
30 and adhesive element 40 may be produced to have differing
dimensions within the scope of the present invention.
The materials selected for second textile element 30 may vary to
include any of the materials suitable for first textile element 20.
In general, first textile element 20 and second textile element 30
are joined to provide a benefit relating to a combination of the
different materials. For example, first textile element 20 and
second textile element 30 may have different colors or textures to
provide a specific aesthetic appearance, or first textile element
20 and second textile element 30 may be produced from different
materials to enhance abrasion resistance in a specific portion of
article 10. In addition, second textile element 30 may be produced
from a mesh material that forms a vent in article 10. Accordingly,
the material selected for second textile element 30 may vary
significantly within the scope of the present invention to provide
a different property to a portion of article 10.
The materials selected for adhesive element 40 may include any
thermoplastic polymer, for example, as discussed above. A further
consideration regarding adhesive element 40 relates to the manner
in which adhesive element 40 is bonded with first textile element
20 in the second step, described hereafter. In general, heat and
pressure are applied to form the bond. If adhesive element 40 were
merely a thermoplastic polymer material, a portion of the polymer
may bond with or otherwise engage the structure that applies the
heat and pressure. In order to alleviate this possibility, a
carrier sheet may be applied to one surface of adhesive element 40.
The carrier sheet may be paper, a polymer having a higher melting
temperature, or any other material that would effectively prevent
molten portions of adhesive element 40 from engaging the structure
that applies the heat and pressure.
Second Step--Forming the First Bond
The second step in the method is generally depicted in FIGS. 7 and
8 and involves forming a first bond between first textile element
20 and adhesive element 40. With reference to FIG. 7, first textile
element 20 and adhesive element 40 are depicted as being positioned
adjacent to each other and between a surface 51 and a platen 52 of
a bonding apparatus. Surface 51 may be a stationary component of
the bonding apparatus upon which first textile element 20 and
adhesive element 40 are placed. Platen 52, which is heated to an
appropriate temperature, then translates toward surface 51 and
compresses first textile element 20 and adhesive element 40 against
surface 51. The combination of the heat and pressure supplied by
platen 52 elevates the temperature of adhesive element 40 and
ensures contact between first textile element 20 and adhesive
element 40, thereby causing a portion of adhesive element 40 to
infiltrate the structure of first textile element 20. Upon
subsequent cooling, a portion of adhesive element 40 solidifies
around the individual fibers or filaments in first textile element
20, thereby forming the first bond. FIG. 8 depicts adhesive element
40 in a bonded relationship with first textile element 20 following
the second step.
The bonding apparatus depicted in FIG. 7 is intended to provide one
example of a structure suitable for forming the first bond.
Alternately, surface 51 may be replaced by another heated platen,
for example. Heat supplied through conduction is not the only
method for forming the first bond. Radio frequency and ultrasonic
bonding may also be utilized to form the first bond, which may
require a substantially different type of bonding apparatus.
The degree of heat utilized to melt adhesive element 40 is
primarily dependent upon the materials forming first textile
element 20 and adhesive element 40. As an initial consideration,
the degree of heat should not melt or otherwise damage first
textile element 20 prior to the melting of adhesive element 40,
unless such melting of first textile element 20 is intended for
forming the first bond. This consideration aside, however, the
degree of heat and pressure is generally related to the specific
material forming adhesive element 40. For example, a temperature of
350.degree. Fahrenheit and a pressure of 40 pounds per square inch
that is applied for 15 seconds is generally sufficient to form the
first bond when adhesive element 40 is a polyurethane material.
Similarly, a temperature between 325 and 375.degree. Fahrenheit and
a pressure between 60 and 80 pounds per square inch that is applied
for a time between 10 and 15 seconds is generally sufficient to
form the first bond when adhesive element 40 is a vinyl or
polyamide material.
Third Step--Defining the Aperture
The third step in the method is generally depicted in FIG. 9 and
involves defining apertures 23 and 43 through first textile element
20 and adhesive element 40, respectively. Apertures 23 and 43 have
been discussed as separate apertures due to their formation through
two separate elements. In effect, however, the step of defining
apertures 23 and 43 provides a single aperture that extends through
both first textile element 20 and adhesive element 40.
A die cutting operation or any other operation suitable for
removing a portion of adhesive element 40 and a corresponding
portion of first textile element 20 may be utilized to define
apertures 23 and 43. In general, apertures 23 and 43 are defined in
the portion of article 10 where adhesive element 40 is bonded to
first textile element 20. During the second step, adhesive element
40 is bonded to first textile element 20, which defines a bonded
area and an unbonded area. The bonded area is, therefore, the
portion where first textile element 20 and adhesive element 40 are
bonded, and the unbonded area is the portion of first textile
element 20 that is not bonded to adhesive element 40. Accordingly,
apertures 23 and 43 are defined through the bonded area.
The general purpose of adhesive element 40 is to join first textile
element 20 and second textile element 30 around apertures 23 and
43. Accordingly, apertures 23 and 43 are defined in a manner that
leaves a portion of adhesive element 40 extending entirely around
aperture 23. The shape of apertures 23 and 43 may be proportioned
to have the same shape as second textile element 30, but with
lesser dimensions. This configuration ensures that apertures 23 and
43 fit entirely within the bonded area. The shape of apertures 23
and 43 may also be such that the remaining portion of adhesive
element 40 has a uniform width between edges 41 and 42.
Alternately, many apertures may be defined through first textile
element 20 and adhesive element 40, as in article 10a.
Adhesive element 40 may include a carrier sheet, as discussed
above. During the third step of the method, the carrier sheet may
be removed in order to prepare adhesive element 40 for bonding with
second textile element 30 in the fourth step of the method.
Fourth Step--Forming the Second Bond
The fourth step in the method is generally depicted in FIG. 10 and
involves forming a second bond between second textile element 30
and adhesive element 40. With reference to FIG. 10, first textile
element 20, second textile element 30, and adhesive element 40 are
depicted as being positioned adjacent to each other and between a
surface 51' and a platen 52' of a bonding apparatus, which may be
the same bonding apparatus utilized during the second step. Surface
51' may be a stationary component of the bonding apparatus. Platen
52', which is heated to an appropriate temperature, then translates
toward surface 51' and compresses second textile element 30 and
adhesive element 40. The combination of the heat and pressure
supplied by platen 52' elevates the temperature of adhesive element
40 and ensures contact between second textile element 30 and
adhesive element 40, thereby causing a portion of adhesive element
40 to infiltrate the structure of second textile element 30. Upon
subsequent cooling, a portion of adhesive element 40 solidifies
around the individual fibers or filaments in second textile element
30, thereby forming the first bond. FIGS. 1 4 depict first textile
element 20, second textile element 30, and adhesive element 40
following the second step.
The melting temperature of adhesive element 40 is generally the
same in the fourth step as during the second step. The same
temperature and pressure may, therefore, be applied to form the
second bond. Depending upon the speed with which the third step is
performed, residual heat may remain within adhesive element 40
prior to the application of heat and pressure in the fourth step.
Accordingly, the time period for the application of the heat and
pressure may be shortened to account for the residual heat.
Further Textile Joining Configurations
With respect to article 10, aperture 23 and aperture 43 are formed
on interior portions of first textile element 20 and adhesive
element 40, respectively. That is, apertures 23 and 43 are spaced
inward from the outer edges of elements 20 and 40. The general
method disclosed above, however, may be applied to configurations
wherein apertures are formed in edge portions of one or more of the
elements. For example, FIG. 11 depicts an article 10b that includes
a first textile element 20b, a second textile element 30b, and an
adhesive element 40b. In forming article 10b, adhesive element 40b
is bonded to first textile element 20b and an aperture, which
corresponds with aperture edge 22b, is defined on an edge portion
of both first textile element 20b and adhesive element 40b, rather
than through interior portions. In other words, the apertures in
first textile element 20b and adhesive element 40b are not spaced
from all outer edges of the elements. Adhesive element 40b is then
utilized to join first textile element 20b with second textile
element 30b. In this configuration, therefore, textile element 40b
extends into an interior portion of article 10b and shares a common
outer edge with first textile element 20b.
Referring to FIG. 12 an article 10c having a first textile element
20c, a second textile element 30c, and an adhesive element 40c is
depicted. An aperture corresponding with aperture edges 22c and
22c' is defined through both first textile element 20c and adhesive
element 40c. Whereas the aperture extends through an interior
portion of first textile element 20c, the aperture is positioned on
an edge portion of adhesive element 40c. Accordingly, adhesive
element 40 only extends partially around the aperture formed
through first textile element 20c and does not extend along the
portion of the aperture defined by aperture edge 22c'. In this
configuration, adhesive element 40c joins first textile element 20c
with second textile element 30c, but a portion of the edge of
second textile element 30c remains unbonded to first textile
element 20c. That is, second textile element 20c remains unbonded
along aperture edge 22c'. This configuration may be utilized, for
example, to provide a pocket or access opening through article
10c.
CONCLUSION
The general method described above may be applied to a wide range
of products to join various textile elements. An article formed
through the method has advantages over articles formed through
conventional sewing techniques. For example, the article may
include textile elements with any practical shape, whether the
shape includes angles, small-radius curves, or other complex
features. From an aesthetic perspective, the ability to join
elements with any practical shape provides the capacity to
incorporate a functional graphic into the article. As discussed
with respect to article 10a, a mesh material may be integrated into
the article that serves to ventilate the article and provide a
specific aesthetic to the article. In addition, edges of the
elements do not need to be surged, hemmed, or turned to prevent
unraveling or fraying. Furthermore, the seams generally have a
thickness of two textile layers, rather than the three or more
produced through conventional sewing techniques.
The present invention is disclosed above and in the accompanying
drawings with reference to a variety of embodiments. The purpose
served by the disclosure, however, is to provide an example of the
various features and concepts related to the invention, not to
limit the scope of the invention. One skilled in the relevant art
will recognize that numerous variations and modifications may be
made to the embodiments described above without departing from the
scope of the present invention, as defined by the appended
claims.
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